Variable Speed Taping Machine for High Throughput
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Solution Overview
Problem
Existing taping machines face limitations in throughput and tape application quality due to high conveyor speeds during critical phases of tape application on vertical sides, leading to potential damage or incomplete adhesion, especially when handling long boxes.
Innovation Solution
A taping machine with a drive system that adjusts feed speed using sensors to detect box surfaces and programmable logic to create customizable speed profiles, allowing for reduced speed during critical phases and increased speed during other phases of the taping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high conveyor speed is maintained during tape application, then throughput is improved, but tape adhesion quality deteriorates due to insufficient contact time and potential damage
Solution Approach 1:
The conveyor system transitions from static constant speed operation to dynamic variable speed operation. The drive system automatically adjusts the conveyor speed based on the position of the box relative to the tape applicator, reducing speed during critical tape application phases and increasing speed during non-critical phases, thereby resolving the contradiction between throughput and adhesion quality
Solution Approach 2:
The system changes the operational parameter (conveyor speed) dynamically during the taping process. By modulating the speed parameter in response to detected box positions and tape application stages, the system optimizes both productivity and quality - maintaining high speed when quality requirements are lower and reducing speed when precise tape adhesion is critical
2Manufacturing precision
If conveyor speed is reduced during critical phases, then tape adhesion quality is improved, but throughput deteriorates due to slower overall processing
Solution Approach 1:
The conveyor operates in periodic cycles of high and low speed. During each box processing cycle, the system alternates between high-speed conveyance (when quality requirements are minimal) and low-speed tape application (when quality is critical). This periodic speed variation ensures high adhesion quality during essential phases while maintaining high overall throughput through rapid conveyance during non-critical phases
Solution Approach 2:
The taping process is segmented into distinct phases with different speed requirements. The system identifies and separates the critical tape application phases from non-critical conveyance phases, applying different speed regimes to each segment. This segmentation allows the system to optimize for quality where needed and for speed where acceptable, resolving the throughput-quality trade-off
3Loss of time
If high conveyor speed is used, then processing time is reduced, but tape application completeness deteriorates due to insufficient contact duration
Solution Approach 1:
The conveyor speed is dynamically adjusted based on the real-time position of the box and the stage of tape application. During the critical initial and final contact phases where completeness is most vulnerable, the speed is automatically reduced to ensure sufficient contact duration. During intermediate phases where the tape is already securely applied, speed increases to minimize overall processing time, thus ensuring completeness without excessive time loss
Data Source
Figure 1~2
Figure 3~4
AI summary
It is disclosed a taping method and a taping machine comprising a conveying mechanism which defines a sliding plane (20), for conveying a plurality of boxes (S) to be sealed with adhesive tape. The taping machine comprises at least a conveying unit (30) for the displacement of said boxes (S), set in motion by an actuator (31) controlled by a drive (32), at least a tape applicator (4, 5) provided above said sliding plane, meant to apply sealing adhesive tape on said plurality of boxes (S) during the displacement thereof, a passage sensor (33), arranged fixed with respect to said sliding plane, apt to detect the moving position of at least a vertical surface of said boxes (S) and output a respective sensor signal, and it further comprises a programmable logic unit (34) interfaced with passage sensor (33) and said drive (32) wherein a current position of both a front vertical surface and a rear vertical surface of said boxes (S) is computed based on said at least a sensor signal, and wherein an actuator control function (F) is implemented to act on said drive (32) controlling the actuator (31), said actuator control function (F) being variable in time on the basis of said current position of both a front vertical surface and a rear vertical surface of said boxes (S).